Reaming and fine boring EasyAdjust-System Simpler, faster, more cost-effective
Never before it had been possible to adjust tools so fast and at such a precision. 2
MAPAL EasyAdjust-System Introduction The new EasyAdjust-System simple setting of tools in a minimum of time A drastic reduction in the setting time for tools with guide pad technology was the goal of the latest new development from MAPAL the EasyAdjust-System. The heart of the EasyAdjust-System is an innovative cassette that stably holds the blades with their six or four cutting edges without any play. The back taper of the minor cutting edge is already integrated into this cassette, thus eliminated the need for this adjustment. Thanks to the exact guidance of the cassette on a precision guide pin, the back taper remains unchanged even during diameter adjustments. Matching cassettes are available for different back tapers that can be selected and employed, depending on the application irrespective of the blade and the tool. Introduction 3 System overview 4 Machining example 6 Article overview 8 Handling instructions 10 Significant economic benefits In practice this system offers economic benefits: The HX-blades with six useful cutting edges can be inserted quickly and precisely in cassettes with different back tapers. Tools with EasyAdjust-System only have to be adjusted in diameter. That increases process reliability at blade changes an effect that becomes all the more significant, the more blades are installed in a tool. And the time for adjustment per blade is reduced to a fraction by the new development! Advantages: Setting time drastically reduced only the diameter of the tools still has to be adjusted. Cost-effectiveness, handling and process reliability significantly increased Precision remains high 3
MAPAL EasyAdjust-System System overview System overview The EasyAdjust-System in detail Clamping jaw with threaded spindle Precision guide pin HX blade with clamping groove Cassette Threaded pin and adjusting wedge The EasyAdjust-System consists of a precision cassette which holds the blade. The cassette is guided by a precision guide pin during adjustment. A clamping groove which together with the clamping jaw forms a force closure system ensures that the blade is securely retained. Tools with EasyAdjust-System only have to be adjusted in diameter. The back taper is already integrated into the cassette and remains unchanged at diameter changes. Advantages: Half the setting time for blades Exact guidance of the system on precision guide pin Back taper already integrated into the cassette Optimum cutting material utilisation thanks to blades with four and six cutting edges Comparison of the setting times The time for adjustment per blade can be drastically reduced by the new development. New EasyAdjust-System Conventional systems 4
MAPAL EasyAdjust-System System overview Back taper The back taper of the blade has a major influence on the bore quality. MAPAL selects the back taper of the cassette necessary for the machining application according to the demands of the material and the feed rate. Advantages: back taper Adaptation of the back taper, irrespective of blade and tool body Production of defined roughnesses thanks to different back tapers Optimum surface finish for downstream processes (for example honing) Two variants of the indexable blades The EasyAdjust-System if available with two different blade types for through bores and blind bores. HX-blade TEC-blade The HX-blade with six cutting edges for high cost-effectiveness. The TEC-blade with four cutting edges and different lead geometries for blind bore and shoulder machining. Through bore Suitable for open bores. Not suitable for machining shoulders if 90 are required. Shoulder blind bore Suitable for closed bores and machining shoulders taking into account the cutting edge length. 5
MAPAL EasyAdjust-System Machining example Machining example with the EasyAdjust-System Precision tools for connecting rod machining Optimum surface qualities and a high level of dimensional consistency within close tolerances are demanded when machining the small and large pin bores of connecting rods. Fine boring tools with guide pads and EasyAdjust-System solve this difficult machining task precisely and cost-effectively. An additional measuring system on the machine and final finish-machining by honing become superfluous. Consistently high tool lives of the cutting edges with high precision are achieved even with minimum quantity lubrication (MQL). Combination tools for rough machining and finish machining of the small and large pin bores The tool combinations are equipped with ISO inserts for rough machining and HX blades with EasyAdjust-System for fine machining. In particular, modern lightweight connecting rods such as tapered or basket handle conrods can be machined completely. The chamfered or stepped side surfaces of the small pin bore result in interrupted cutting conditions and hence in more difficult machining conditions at the inlet and outlet during the machining of the bore. The tools with guide pads and EasyAdjust-System are able to perform this machining completely in one step both cost-effectively and precisely. Semi-machining and finish machining of the crankshaft bearing bore Cylinder crankcases for car and motorbike engines are today generally made of aluminium. The matching bearing covers, however, are often made of spheroidal graphite cast iron (GGG) or sintered steel. This bimetallic combination demands high guide accuracy in order to ensure perfect circularity and cylindricity with varying cutting forces. Special features: Small end: Tapered or basket handle form High demands on the form and surface finish Unfavourable lead situation due to the interrupted cut High demands on axis parallelism Back taper of D cassette Pilot machining Short, stable pilot tool for exact positioning and supporting for the subsequent machining. Thanks to the high precision of the tool, timeconsuming presetting with guide bearings can be waived on machining centres. Parts requiring no subsequent honing can be finish-machined ready for assembly with this pad-guided fine boring tool. Fine machining The up to 1200 mm long fine boring tool for the machining of the other ribs is inserted vertically through the first and/or second rib and machines the remaining bores with the highest precision with respect to straightness, parallelism and roundness. Thanks to simple and reliable handling of the blade adjustment, production is easily possible within an IT5 tolerance band. Special features: Four-blade: High feed rates, large savings in time Ideal starting situation for subsequent honing Bimetal combinations aluminium/ spheroidal graphite cast iron Back taper of M cassette 6
MAPAL EasyAdjust-System Machining example Cost-effective machining of cylinder bores No matter whether GGV, GG or thermally sprayed coatings, the machining of the cylinder bore in engine blocks makes high demands on the fine boring tool in order to ensure that roundness and cylindrical form even in the delicate water jacket area. The boring of the cylinders represents a challenge not only from the point of view of quality demands, but also with respect to the machining time. Micro machining Using the six cutting edge tools with the cut distribution "micro machining 4+2", feed rates of over 1,200 mm/min are possible thanks to PcBN cutting material. With their rapid and high-precision adjustment, the six cutting edges of the HX blade can achieve a total tool life of up to 24,000 bores per blade. With the short setting times of the EasyAdjust-System, the non-productive times can be very greatly reduced with this multi-bladed tool. Special features: Micro machining (4 semi-machining and 2 finish-machining blades) 4,000 bores per cutting edge Blind bores in transmission cases and valve housings Back taper of P and D cassette Valve housings are the control centres in the hydraulics sector. The spool bores with their innumerable transverse galleries have to be machines with µ precision with respect to straightness, surface finish and dimensional tolerances. Rectangularity and smoothness, high surface finish quality and minimum circularity deviations with exact positions and concentricity are preconditions for comfort and durability of transmission parts. Special features: Multi-stage fine boring tools With the precision-ground TEC-blade, workpiece finishing is quick and easy with minimum burr as the burr root is soft and easy to remove. Alternating cutting depths from diameter to face machining demand stable guidance of the tools as with the fine boring tools with guide pad technology of the EasyAdjust System. Finish-machining by honing can be eliminated thanks to the latest cutting materials and geometries. Machining of valve housing: Straightness 0.006 Surface finish Ra 0.6 Dimensional accuracy IT5, IT6 Back taper of D cassette 7
MAPAL EasyAdjust-System Article overview Article overview EasyAdjust-System with HX-blades Selection criteria System sizes Type of bore ø-tool range Graduation of the back taper* Blade type Cutting edge size System designation Through bore from ø 20 B Particular demands Back taper HX 2 EAS-62-B * Selection by agreement with MAPAL, depending on the demands of the part. D F Recommended standard + + EAS-62-D EAS-62-F H Particular demands EAS-62-H K M P R EAS-62-K EAS-62-M EAS-62-P EAS-62-R from ø 30 B Particular demands Back taper 3 EAS-63-B D F Recommended standard EAS-63-D EAS-63-F H Particular demands EAS-63-H K M P R EAS-63-K EAS-63-M EAS-63-P EAS-63-R HX-Blades for EasyAdjust-System, six cutting edge Carbide PcBN PcBN P M K S K N Cutting material HP342 CP122 HP342 HC413 HP342 HP615 FU485 PU620 Type Size HX 2 30538938 30538934 30538938 30009396 30538941 HX 2 HX128RLB 30308283 HX128RLB HX128RLB On request 30538957 HX 3 30538992 30538999 30538992 30008170 30538988 HX 3 HX138RLB 30304830 HX138RLB HX138RLB On request 30539009 Available from stock in Germany No stocking of standard blades (delivery time on request) Dimensions in mm 8
MAPAL EasyAdjust-System Article overview Article overview EasyAdjust-System with TEC-blades Selection criteria System sizes Type of bore ø-tool range Graduation of the back taper* Blade type Cutting edge size System designation Blind bore / shoulder from ø 20 B Particular demands Back taper TEC 2 EAS-42-B D F Recommended standard + + EAS-42-D EAS-42-F H Particular demands EAS-42-H K M P R EAS-42-K EAS-42-M EAS-42-P EAS-42-R from ø 30 B Particular demands Back taper 3 EAS-43-B D F Recommended standard EAS-43-D EAS-43-F H Particular demands EAS-43-H K M P R EAS-43-K EAS-43-M EAS-43-P EAS-43-R * Selection by agreement with MAPAL, depending on the demands of the part TEC-Blades for EasyAdjust-System, four cutting edge Carbide PcBN PcBN P M K S K N Cutting material HP342 CP140 HP342 HC413 HP342 HP615 FU485 PU620 Type Size TEC 2 30539018 30539023 30539018 30539027 30539029 TEC 2 30539030 30539033 30539030 30539030 30539032 30539034 TEC 3 30539038 30539037 30539038 30539044 30539039 30539040 TEC 3 30539043 30539045 30539043 30539043 30539046 Available from stock in Germany No stocking of standard blades (delivery time on request) Dimensions in mm. 9
MAPAL EasyAdjust-System Handling instructions Handling instructions Replacing and setting the blade The EasyAdjust-System permits quick and easy replacement of the blades. The blades are replaced and set with µ precision in just a few steps. 1 2 1 Loosen the adjusting wedge by turning it half a turn in anti-clockwise direction using an allen key. 2 Note: Two allen keys are required. Loosen the clamping jaw by turning Allen key 1 in anti-clockwise direction while turning allen key 2 in clockwise direction. 3 Push the cassette together with the adjusting wedge forward towards the tool. 1 2 4 Remove the blade from the cassette. 5 Replace or turn the blade and then press 6 Note: the blade into the cassette. Two Allen keys are required. Tighten the clamping jaw by turning allen key 1 in clockwise direction while turning allen key 2 in anti-clockwise direction. 10
MAPAL EasyAdjust-System Handling instructions Clamping jaw with threaded spindlel HX-blade with clamping groove Clamping jaw with threaded spindle HX-blade with clamping groove Cassette Cassette Precision guide pin Threaded pin and adjusting wedge Threaded pin and adjusting wedge Precision guide pinl 1 7 Note: You can now proceed with either the protrusion measurement or the absolute measurement. 8 Move the measuring sensor to the highest point of the blade. Clamp the tool in the mount of a setting device. Move the measuring sensor to the highest point of the guide pad and zero the measured value at this point. 9 Set the protrusion dimension or absolute dimension of the blade by turning the threaded pin in clockwise direction using an allen key. Result: The desired protrusion or absolute dimension of the blade is set. 11
MAPAL the major specialist Reaming and fine boring Boring Drilling Milling Turning Actuating Clamping Setting and measuring Services V1.0.0 MAPAL Präzisionswerkzeuge Dr. Kress KG P.O. Box 1520 D-73405 Aalen Phone +49 (0) 7361 585-0 Fax +49 (0) 7361 585-150 info@de.mapal.com www.mapal.com EAS-E-01-020-0913-HD Printed in Germany. Right of technical modifiations reserved.